Radial interlocking refractory tuyere block

ABSTRACT

A two section refractory block for lining a horizontal cylindrical furnace, such as a copper converter, one section containing a nonradial tuyere for said converter. The two sections of the block are held in abutting relationship to form a boundary extending from the inner radial wall of the converter to an outer radial wall. The sections are restrained against relative radial movement by providing a depression in the boundary surface of the tuyere containing section and a complementary protuberance in the boundary surface of the other section.

[151 3,636,872 Jan. 25, 1972 United States Patent Forcier X M 6 6 2 m s u r n O H V n a F O .m m P m d E m 9 a H .m m m 5 E 4 m 5 a 9 m n 3 P [54] RADIAL INTERLOCKING REFRACTORY TUYERE BLOCK [72] Inventor: Roy E. Forcier, Fremont, Calif. Attorney-James E. Wolber and Peter Andrcss ABSTRACT Assignee: International Minerals & Chemical Corporation Jan 29 1970 A two section refractory block for lining a horizontal cylindrical furnace, such as a copper converter, one section contain- 6,667 ing a nonradial tuyere for said converter. The two sections of [22] Filed:

[21] Appl. No.:

the block are held in abutting relationship to form a boundary extending from the inner radial wall of the converter to an outer radial wall. The sections are restrained a gainst relative radial movement by providing a depression in the boundary surface of the tuyere containing section and a complementary 1.01 232 ,2; 5x 2 "2 8 8 m l m5 M NO References Cited protuberance in the boundary surface of the other section.

10 Claims, 2 Drawing Figures UNITED STATES PATENTS 3,084,924 4/1963 Morlock............................. ....266/4l PATENTEUJANZSISYZ 3.636872 FIG. 2

INVENTOR:

ROY E. FO/PC/ER RADIAL INTERLOCKING REFRACTORY TUYERE BLOCK BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to refractory blocks or bricks used as a tuyere for injecting air or the like into a furnace having a curved wall, such as a copper converter.

2. Description of the Prior Art In the construction of horizontal converters, such as, for example, a Pierce-smith" converter, the interior of a horizontal cylindrically shaped converter is lined with wedge-shaped refractory blocks made, for example, of magnesite, or a mixture of magnesite and chrome ore. Such converters are described, inter alia, in Samans, Engineering Metals and Their Alloys (1949), and generally include a number of tuyeres. During the conversion of copper matte into blister copper in the converter, air or oxygen is added in order to oxidize the sulphur and iron in the converter. Typically, a tuyere provides the ingress through one or more of the refractory blocks. The converting process in the case of copper matte is exothermic and supplies all of the heat required.

Ideally, the tuyere should be made of a single block in order to avoid unnecessary scams or joints which can cause increased spall and erosion loss of the refractory blocks. Furthermore, due to the curved or voussoir shape of the converter, it is desirable to use tapered or radial blocks having radial joints so that the assembled lining tends to be self-supporting and resists falling inward into the converter. The furnace is charged with tuyeres above the metal level. Air is turned on and converter rotated to bring tuyeres under the metal. Thus the oxygen can be injected directly at the molten copper matte in the bottom of the converter.

The size of the refractory blocks, which are large enough to contain the entirety of a nonradial tuyere, presents difficulties with respect to distortions or warpage during fabrication of the blocks. As the size of the blocks increases, so do the difficulties of pressing, drying, and firing the blocks. Thus, as the blocks are made smaller the distortion decreases; and yet, ideally, the blocks should be large enough to permit the tuyere to extend through a single block in the proper direction.

Two or four piece tuyeres have commonly been used, but these have obvious drawbacks. Tuyeres having longitudinal seams risk undue attrition due to spalling and erosion.

It is a primary object of this invention to provide a refractory block having a configuration such that a reasonably sized one-piece nonradial tuyere can be formed therein, and which when used with a companion shape as described together form a larger radial assemblage.

A further object of this invention is to provide a composite block' having a nonradial tuyere wherein the sections of the block are of a reduced size to minimize distortions and warpage during fabrication.

A still further object of this invention is to provide a composite block, one section of which contains the entirety of the tuyere and the other section of which is of a complementary shape so that the composite forms a customary wedge or radially shaped block.

Another object of this invention is to provide a two section refractory block wherein relative radial movement between the two sections is precluded by the interlocking configuration of the sections.

Yet another object of this invention is to provide an economical refractory block of sturdy construction having a seamless tuyere, which tuyere does not intersect any of the seams or joints of the adjacent blocks.

SUMMARY With these and other objects in mind a block in accordance with the invention includes two sections with the tuyere being positioned entirely in one of said sections. The two sections have adjacent sides in abutting relationship to form a boundary extending from'the inner to the radially spaced outer wall of the furnace. Facilities are provided for restraining the sections against relative radial movement along said boundary.

DRAWINGS Other objects, advantages, and aspects of the invention will become apparent by reference to the following detailed description of the invention and drawings of specific embodiments thereof wherein:

' FIG. 1 is a vertical cross section taken through a horizontal cylindrically shaped furnace with portions removed and showing a one piece tuyere and complementary skew shaped block in accordance with the invention; and

FIG. 2 is an exploded detailed view of the tuyere and the complementary skew-shaped block.

DESCRIPTION OF THE INVENTION Referring to FIG. 1 there is shown a portion of a horizontal generally cylindrically shaped, furnace, designated 10. The invention will be described with respect to furnaces used in the pyrometallurgical extraction of copper from its ores, but it is to be understood that this is by way of example and not limitation. Typically, the furnace or converter 10 is charged with copper matte through an opening 11 in the top of the furnace. A high temperature conversion takes place in the furnace 10 which results in the formation of blister copper. In order for the reaction to take place it is necessary to inject air or oxygen into the furnace through openings or tuyeres 8 (one shown) positioned in the lower half of the cylindrical furnace. In the embodiment show, thetuyere is formed by merely providing an opening in the refractory block. However, it is to be understood that the tuyere can also take the form of a metal tube or insert mounted in an opening in the block and through which the air, oxygen or other materials are injected. As can be seen, the furnace includes a plurality of refractory wedge shaped blocks 13 which are similar to those of a voussoir. Typically, the blocks 13 are shaped such that extensions from their sides converge, as shown by the lines 14, to an apex 15 which corresponds with the center line of the furnace. The blocks 13 can be made of magnesite, although other materials will suffice. In practice, it is usual and preferred to provide wedge blocks much smaller than those shown, usually about 4 inches by 4 inches in cross section and 18 inches long. Thus the blocks 13 may be considered composites consisting of four smaller blocks. A suitable backup material 16 such as crushed or grain magnesite can be used if desired to surround the refractory blocks, and the furnace 10 is enclosed in a metal shell 17.

As shown more clearly in FIG. 2, the tuyere block 12 mates with a complementary section 21 so that the two sections form a generally wedge-shaped block similar to the other blocks 13. The tuyere block 12 includes'agenerally horizontal opening or tuyere 22 which extends from a radially inner end 23' to a radially outer end 24. It is to be understood that the angle of the opening 22 can be various angles depending on the particular parameters involved in furnace construction, but will be at a substantialangle to side 25 of tuyere block 12 and side 36 of block 21. Preferably, the center line of the opening 22 should be directed along a line falling below the theoretical center of the furnace in order for the air being introduced therethrough to be most effective. The tuyere may be of any desired diameter provided the thickness of the tuyere block and complementary section are adjusted to accommodate the tuyere. Tuyere diameters of 2 inches to 3 inches are common.

The tuyere block 12 has a side'25 and a side 26 which are complementary with side 27 of the complementary section 21. In order to prevent relative movement between the tuyere block 12 and the complementary section 21, it is desirable to provide a-notch portion 28 in side 26 thereof. This can be accomplished by providinga projecting portion 29 on the tuyere block 12 so that the resulting V-shape for the side 26 is achieved. The projecting portion 31 of side 26 is preferably radial, as are the sides 25 and 36 of tuyere block 12 and complementary section 21.

The complementary or skew section 21 is in abutting relationship with the side 26 throughout the entire length thereof so that necessarily the portion 34 of side 27 forms an angle with the remainder of the side 27. The complementary section 21 also includes an outer side 36 which is in abutting relationship with the adjacent block 13. Additionally, section 21 has an inner radial spaced end 37 and an outer radially spaced end 38. [f the inner radial ends 23 and 37 total approximately 17 inches in length and the outer radial ends 24 and 38 total approximately 22 inches in length, the angled portions 31 and 34 of mating sides 26 and 27 will both be about 6 inches in length, measured radially. This dimensioning will provide sufficient strength to avoid relative radial movement between the tuyere block 12 and the complementary section 21. It is desirable that the portions 31 and 34 formed in the block 12 and section 21 extend radially outward since as the converter lining wears down to a thickness less than 6 inches, for example, 12 and 21 will still be taper keyed to the same extent as the rest of the lining, and should not be subject to premature dislodging at that point.

When the tuyere block 12 and complementary section 21 are assembled in abutting relationship, the sides 25 and 36 are angularly spaced to form a wedge-shaped block similar to blocks 13. The theoretical extensions of sides 25 and 36 would intersect at the center of the furnace 10, as would the extension of abutting portions 31 and 34. Thus, the tuyere blocks present no special handling problems beyond those with the customary wedge shape.

It will be noted that the boundary surface formed between the surfaces 26 and 27 extends generally parallel to the longitudinal axis of the opening 22. It is to be understood that this is merely the preferred embodiment and that numerous other geometrical configurations are possible in order to prevent the relative radial movement of the block sections 12 and 21. For example, the boundary surface between the sections 12 and 21 could be in the form of a continuous curve wherein the tuyere section 12 had a rounded valley and the skew section 21 had a curved protuberance complementary therewith. It is merely necessary that the abutting boundary surfaces 26 and 27 be nonplanar in order to prevent relative radial movement therebetween. By nonplanar it is meant that either the tuyere block or the complementary section should have a projection or protuberance which is received in a complementary recess or notch in the other section so as to prevent either of the sections from sliding radially inward into the interior of the furnace.

Alternatively, the mating, complementary surfaces of the tuyere block and complementary section may be planar, but with both mating surfaces plated with thin sheet metal so that when heated in place in normal furnace operation, the desired bond will be formed. The plating of refractory bodies, per se, is well known in the art.

Iclaim:

1. In a block made of refractory material for lining the curved interior of a furnace wall, said block having generally parallel inner and outer radially spaced ends, two opposed angularly spaced sides, and two generally parallel opposed faces, said block further having a nonradial'tuyere therein, the improvement comprising:

said block being formed of two sections with said tuyere being formed entirely in one of said sections; said sections having sides adapted to mate in abutting relation to form a boundary surface extending between said parallel faces from said inner to said outer ends, and a major portion of said boundary surface extending in a direction to intersect an extension of a side of said block beyond the outer end thereof; and means for restraining said sections against relative movement in a direction generally perpendicular to said ends. 2. A block as recited in claim 1 wherein said boundary surface is nonplanar to prevent either of said sections from sliding in a direction perpendicular to said faces.

3. In a block made of refractory material for lining the curved interior of a furnace wall said block consisting of two sections and having generally parallel inner and outer radially spaced ends, two opposed angularly spaced sides, and two generally parallel opposed faces, said block further having a nonradial tuyere entirely in one section thereof, and a boundary surface between said sections, said boundary surface including two noncoplanar flat side portions whereby relative movement of said sections in a direction generally perpendicular to said ends is prevented.

4. A block as recited in claim 3 wherein the two flat side portions of the boundary surface intersect at an obtuse angle.

5. A block as recited in claim 3, wherein one portion of said boundary surface is generally parallel to the longitudinal axis of said tuyere,

6. A block as recited in claim 5 in which the other portion of said boundary surface extends in a generally radial direction.

7. A block as recited in claim 3 having a notch formed in the boundary surface of said tuyere containing section, and a protuberance complementary to said notch formed in the boundary surface of the other section.

8. In a cylindrical furnace having a curved interior lining of refractory blocks, the improvement comprising:

a composite block being formed of two sections with a nonradial tuyere being formed entirely in one of said sections;

said composite block having inner and outer radially spaced ends, two generally parallel opposed faces and two an gularly spaced sides;

said sections having adjacent sides in abutting relation to form a boundary surface extending between said parallel faces from said inner to said outer ends, and a major portion of said boundary surface extending in a direction to intersect an extension of a side of said block beyond the outer end thereof; and

means for restraining said sections against relative radial movement along said boundary surface.

9. A furnace as recited in claim 8 wherein said restraining means includes a recess formed in the boundary surface of one of said sections and a projection complementary to said recess formed in the boundary surface of the other section.

10. A furnace as recited in claim 8 wherein said restraining means includes a first boundary surface portion extending generally parallel to said tuyere and a second boundary surface portion extending generally radially of said cylindrical furnace, said first surface portion being disposed radially inward of said second surface portion. 

1. In a block made of refractory material for lining the curved interior of a furnace wall, said block having generally parallel inner and outer radially spaced ends, two opposed angularly spaced sides, and two generally parallel opposed faces, said block further having a nonradial tuyere therein, the improvement comprising: said block being formed of two sections with said tuyere being formed entirely in one of said sections; said sections having sides adapted to mate in abutting relation to form a boundary surface extending between said parallel faces from said inner to said outer ends, and a major portion of said boundary surface extending in a direction to intersect an extension of a side of said block beyond the outer end thereof; and means for restraining said sections against relative movement in a direction generally perpendicular to said ends.
 2. A block as recited in claim 1 wherein said boundary surface is nonplanar to prevent either of said sections from sliding in a direction perpendicular to said faces.
 3. In a block made of refractory material for lining the curved interior of a furnace wall said block consisting of two sections and having generally parallel inner and outer radially spaced ends, two opposed angularly spaced sides, and two generally parallel opposed faces, said block further having a nonradial tuyere entirely in one section thereof, and a boundary surface between said sections, said boundary surface including two noncoplanar flat side portions whereby relative movement of said sections in a direction generally perpendicular to said ends is prevented.
 4. A block as recited in claim 3 wherein the two flat side portions of the boundary surface intersect at an obtuse angle.
 5. A block as recited in claim 3, wherein one portion of said boundary surface is generally parallel to the longitudinal axis of said tuyere.
 6. A block as recited in claim 5 in which the other portion of said boundary surface extends in a generally radial direction.
 7. A block as recited in claim 3 having a notch formed in the boundary surface of said tuyere containing section, and a protuberance complementary to said notch formed in the boundary surface of the other section.
 8. In a cylindrical furnace having a curved interior lining of refractory blocks, the improvement comprising: a composite block being formed of two sections with a nonradial tuyere being formed entirely in one of said sections; said composite block having inner and outer radially spaced ends, two generally parallel opposed faces and two angularly spaced sides; said sections having adjacent sides in abutting relation to form a boundary surface extending between said parallel faces from said inner to said outer ends, and a major portion of said boundary surface extending in a direction to intersect an extension of a side of said block beyond the outer end thereof; and means for restraining said sections against relative radial movement along said boundary surface.
 9. A furnace as recited in claim 8 wherein said restraining means includes a recess formed in the boundary surface of one of said sections and a projection complementary to said recess formed in the boundary surface of the other section.
 10. A furnace as recited in claim 8 wherein said restraining means includes a first boundary surface portion extending generally parallel to said tuyere and a second boundary surface portion extending generally radially of said cylindrical furnace, said first surface portion being disposed radially inward of said second surface portion. 